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> So, You want Boxster Calipers, under 15" wheels..., and you say you have 3" M struts eh?
Aaron Cox
post Oct 14 2007, 08:58 PM
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hmm... lots of people in that boat.

going to later 3.5" struts means, you A ) have to pony up for them (IMG:style_emoticons/default/tongue.gif) B ) use inserts for a heavier 911, or have your 911 units revalved for 914 weight characteristics.

So myself and craig downs sat down and did some thinking.
We wanted to achieve the sleeper look of 15" wheels, but something more modern than M calipers, A calipers, and less expensive than S calipers, AND something you can get parts for (tried getting 951/944 turbo caliper parts lately????)

so we came up with boxsters.... (NON S)
*Fairly Cost effective
*light weight
*pads are double the size
*use readily available 911 carrera rotors
*parts are cheap and available.
*the calipers can be as new as 2003....

So how do you achieve this?

pretty simple. Several mockup sessions behind our favorite mexican food place on lunch breaks.... having the parts... and having a mill.

unlike 3.5" struts, a bolt on solution could not be made to fit under 15" wheels. The 3" ears interfere with the brake pads on the calipers, and spacing them out to clear would require a bigger rotor (951?) and makes 16" wheels mandatory.

Here is what we came up with


The unsuspecting victims.... (fronts and rears.... (rears are going on soon))
Cheap. Light. Newer. Gooder
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one of the jigs, ready to put a step into the strut.
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making a level 'step' for the adapter to lock into and a nice level/true support.
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The finished products, after removing a certain amount of material. Nice and flat and true, lots of surface area (IMG:style_emoticons/default/smile.gif)
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The corresponding step about to be cut into the adapter blocks. 6061 T6 Aluminum.
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fast forward a few to the final products
Attached Image


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DanT
post Oct 14 2007, 09:07 PM
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any plans on giving out the specifics..?

or is this going to be something we will be paying for? (IMG:style_emoticons/default/smile.gif)
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sixnotfour
post Oct 14 2007, 09:15 PM
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Are those really your shoes?
Nice , patent pending
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KaptKaos
post Oct 14 2007, 09:21 PM
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QUOTE(sixnotfour @ Oct 14 2007, 08:15 PM) *

Are those really your shoes?


For years, we have treated to lovely pictures of Aaron's feet. Mostly in flip flops I might add. So give the boy some props as this is a step up on the evolutionary ladder. Next thing you know, he'll be walking upright. (IMG:style_emoticons/default/poke.gif) (IMG:style_emoticons/default/happy11.gif)

Oh, nice brakes too!
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Krieger
post Oct 14 2007, 09:39 PM
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Very nice work, but I have to be a shit stirrer. Won't this cause the same problem you have by adding BMW calipers to the stock 4 set-up, that so many people around here argue? BTW I have done the BMW set up and am strongly in favor of this and what I see in this post. Oh and can't you just use Koni adjustable shocks instead of revalving?
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Aaron Cox
post Oct 14 2007, 10:08 PM
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to answer a few questions...
-914 struts do NOT fit into 3.5" struts to my knowledge. You could use any koni or bilstein or boge designed to fit the later 3.5" housings, BUT they are valved for 911's (heavier). Thus the revalve or???

-Bigger rotor than stock. Its vented and 4mm thicker than standard 911 vented. Should deal with heat fairly well. (IMG:style_emoticons/default/smile.gif) you can engineer a solution to use larger rotors if you wish (IMG:style_emoticons/default/smile.gif) (bigger rotor = 16" wheel.)

-specs. That is up to craig downs. He may be up for sharing the engineering, or maybe even mill your struts and blocks for you? In his hands (IMG:style_emoticons/default/smile.gif)

-shoes. Yes, those are my sexy legs, and beater shoes. OSHA sent me a letter requesting that i use closed toed shoes when working with metal shavings.
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Aaron Cox
post Oct 14 2007, 10:10 PM
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Wheel fitment:

We have tested the fit of
15x6" DEEP six fuchs
15x7 and 8 Fuchs
15x7 and 8 BBS
15x6 NON deep fuch

They all fit with loads of clearance for wheel weights etc (IMG:style_emoticons/default/smile.gif)
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rhodyguy
post Oct 14 2007, 10:50 PM
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Chimp Sanctuary NW. Check it out.
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are you building a track car?
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Aaron Cox
post Oct 14 2007, 10:58 PM
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just overkill, and engineering excercises (IMG:style_emoticons/default/tongue.gif)
goin for uber trick street car...

craigs set is done already (IMG:style_emoticons/default/smile.gif)
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TravisNeff
post Oct 14 2007, 10:59 PM
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That freakin rocks!
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rhodyguy
post Oct 14 2007, 11:00 PM
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Chimp Sanctuary NW. Check it out.
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i see. party on. what does a set of 4 calipers and pads set you back?

k
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Aaron Cox
post Oct 14 2007, 11:05 PM
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QUOTE(rhodyguy @ Oct 14 2007, 10:00 PM) *

i see. party on. what does a set of 4 calipers and pads set you back?

k


market rate is about 300 per end.

depends on how lucky you get.
i am in 5 calipers around 400 bucks (have an extra rear)
pads are about 20-200 bucks depending on what brand (IMG:style_emoticons/default/smile.gif)
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rhodyguy
post Oct 14 2007, 11:11 PM
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Chimp Sanctuary NW. Check it out.
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cool stuff, but too rich for my blood.
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jd74914
post Oct 14 2007, 11:59 PM
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Nice Aaron, I like it.

Will there really be much mechanical advantage over standard M brakes? I mean, they have the same "leverage" on the brake rotors . . .

Besides parts availability, I'm assuming the big advantage of these monoblocks is weight and heat dissipation?


Very cool (IMG:style_emoticons/default/smile.gif) I want a set (IMG:style_emoticons/default/laugh.gif)
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Twystd1
post Oct 15 2007, 12:14 AM
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Awww Hell,

I did the same thing with JB weld and a couple of aluminum prescott seals mixed with spersionate...

And a pocket knife to carve em JUST RIGHT. (Like a Turkey (IMG:style_emoticons/default/blink.gif) )


Then I crashed the car... Oh well.... Maybe I will try your way......

AA and Craig.... You guys rock.

And your your friggin phone cut out while I was talking to Craig. AGAIN. (IMG:style_emoticons/default/chair.gif)

OH... And about your carb puddling while idling. Thats a blocked idle jet.

Thats what happens.

AND / OR your floats are high. (Like you on glue...fool)

Good job fellas...!!!! Now where the hell are mine..???? (IMG:style_emoticons/default/aktion035.gif)

Claytonobitch
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Brando
post Oct 15 2007, 04:03 AM
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BUY MY SPARE KIDNEY!!!
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Holy shnap, that shit came out good bro (IMG:style_emoticons/default/clap56.gif)

Maybe Iff'n when I ever have the ability (read: $$$) to go 5-lug I'll invest a few dollars in Craig if he's willing to do a few of these for people...
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woobn8r
post Oct 15 2007, 08:50 AM
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Nice Job,

They look almost like the Boxter brake set up I bought from Rich....
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siverson
post Oct 15 2007, 10:03 AM
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Great work!
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brer
post Oct 15 2007, 11:17 AM
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Nice! but ugly.


(IMG:style_emoticons/default/wink.gif)
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Brian Mifsud
post Oct 15 2007, 11:42 AM
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QUOTE(brer @ Oct 15 2007, 10:17 AM) *

Nice! but ugly.


(IMG:style_emoticons/default/wink.gif)


(IMG:style_emoticons/default/agree.gif) so, skipping your feelings about Aaron's legs, what do you think about the calipers? (IMG:style_emoticons/default/laugh.gif)

Nice work Aaron. I like the idea of keeping the 15" wheels..16's are very 80's and anything bigger just looks wrong on the 70's icon the 914 is IHMO..
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